Supercritical catalytic converter

Abstract

An integrated thermal processing and energy conversion system includes a supercritical water oxidation (SCWO) reactor configured to oxidize liquid chemical waste at supercritical conditions, producing heat, CO2, and a mineral-rich slurry. A thermal recovery and storage unit captures heat from the SCWO reactor and uses it to heat pressurized supercritical CO2 (SCCO2), which is expanded through an SCCO2 turbine to generate mechanical and electrical power. The system includes a dry gas fractionator to separate SCCO2 gas from the slurry, a mineral carbonate generator to convert slurry and CO2 into dry mineral carbonates, and a recuperator for recovering additional heat. Cooled CO2 is compressed and stored or directed to a gas mixer for reuse in the SCWO process. Control systems coordinate temperature, pressure, and flow throughout the system. The configuration enables continuous waste treatment, heat recovery, and power generation from interconnected fluid and thermal streams.

What is claimed is: 
     
         1 . A system for thermal processing and energy generation, comprising:
 a supercritical water oxidation (SCWO) reactor configured to receive a mixture comprising water and a carbon-based waste stream and to oxidize the carbon-based waste at a temperature and pressure above a critical point of water, thereby producing an effluent stream comprising supercritical water, carbon dioxide, and heat;   a heating unit thermally coupled to the SCWO reactor and configured to supply thermal energy sufficient to maintain the temperature and pressure of the SCWO reactor above the critical point of water;   a supercritical carbon dioxide (SCCO2) turbine fluidly coupled to the SCWO reactor and configured to receive supercritical carbon dioxide generated by the SCWO reactor, expand the supercritical carbon dioxide to produce mechanical energy, and discharge a turbine exhaust stream; and   a generator mechanically coupled to the SCCO2 turbine and configured to convert the mechanical energy into electrical energy.   
     
     
         2 . The system of  claim 1 , further comprising a thermal transfer unit fluidly and thermally coupled to the SCWO reactor and the SCCO2 turbine, the thermal transfer unit configured to receive heat and carbon dioxide from the SCWO reactor and transfer the heat to a pressurized carbon dioxide stream to generate the supercritical carbon dioxide supplied to the SCCO2 turbine. 
     
     
         3 . The system of  claim 1 , further comprising a control system operatively coupled to the SCWO reactor, the heating unit, and the SCCO2 turbine, the control system comprising a computing device programmed to regulate the operation of the heating unit to maintain supercritical conditions within the SCWO reactor and to control a flow of SCCO2 into the SCCO2 turbine based on one or more measured operating parameters. 
     
     
         4 . The system of  claim 1 , further comprising:
 a thermal recovery unit configured to receive a turbine exhaust stream from the SCCO2 turbine, extract residual heat from the turbine exhaust stream, and produce a cooled carbon dioxide stream; and   a carbon dioxide compressor fluidly coupled to the thermal recovery unit and configured to pressurize the cooled carbon dioxide stream for storage or recirculation.   
     
     
         5 . The system of  claim 1 , further comprising a gas mixer configured to receive carbon dioxide from the SCCO2 turbine or a carbon dioxide compressor and to combine the carbon dioxide with one or more additional gases to produce a mixed gas stream for introduction into the SCWO reactor. 
     
     
         6 . The system of  claim 1 , wherein the heating unit comprises a solar thermal collector configured to concentrate solar energy and transfer thermal energy to the SCWO reactor to maintain the temperature and pressure above the critical point of water. 
     
     
         7 . The system of  claim 1 , further comprising an emissions control system fluidly coupled to the SCWO reactor and configured to receive gaseous byproducts from the reactor and remove or neutralize one or more target compounds prior to atmospheric release. 
     
     
         8 . The system of  claim 1 , wherein the generator is electrically coupled to a power phase synchronizer configured to match the phase, voltage, and frequency of a generated electrical output of the generator to an external electrical grid. 
     
     
         9 . The system of  claim 1 , further comprising a power distribution bus electrically connected to the generator and configured to distribute electrical power to one or more downstream loads. 
     
     
         10 . The system of  claim 1 , wherein the SCCO2 turbine is configured to discharge an exhaust stream, and further comprising a regenerative steam turbine thermally coupled to the exhaust stream and configured to convert residual thermal energy into additional mechanical or electrical power. 
     
     
         11 . A method of operating a thermal processing and energy generation system, comprising:
 initiating operation of a supercritical water oxidation (SCWO) reactor by controlling a heating unit to elevate a temperature and pressure within the reactor above a critical point of water;   delivering a mixture comprising water and carbon-based waste into the SCWO reactor and controlling an injection of an oxidizing agent to facilitate oxidation of the carbon-based waste under supercritical conditions, thereby generating heat and producing an effluent stream comprising carbon dioxide;   heating a pressurized carbon dioxide stream using heat generated by the SCWO reactor to produce supercritical carbon dioxide (SCCO2);   directing the SCCO2 to an SCOO2 turbine and controlling a flow of SCCO2 into the turbine to cause expansion of the SCCO2 and generation of mechanical energy; and   operating a generator mechanically coupled to the turbine to convert the mechanical energy into electrical energy.   
     
     
         12 . The method of  claim 11 , further comprising controlling a thermal recovery unit to receive an exhaust stream from the SCCO2 turbine, extract residual heat from the exhaust stream, and produce a cooled carbon dioxide stream. 
     
     
         13 . The method of  claim 11 , further comprising operating a carbon dioxide compressor to receive and pressurize a cooled carbon dioxide stream for recirculation or storage. 
     
     
         14 . The method of  claim 11 , further comprising controlling a gas mixer to receive the carbon dioxide from the turbine and to combine the carbon dioxide with an oxidizing agent to form a mixed gas stream for reintroduction into the SCWO reactor. 
     
     
         15 . The method of  claim 11 , further comprising regulating an electrical output from the generator by controlling a power phase synchronizer to match a voltage, frequency, and phase of the output to an external electrical grid. 
     
     
         16 . A non-transitory, computer-readable medium containing instructions that, when executed by a hardware-based processor, causes the processor to perform stages for operating a thermal processing and energy generation system, the stages comprising:
 initiating operation of a supercritical water oxidation (SCWO) reactor by activating a heating unit to elevate a reactor temperature and pressure above a critical point of water;   causing one or more pumps or valves to deliver a mixture comprising water and carbon-based waste into the SCWO reactor;   causing an oxidant injection system to deliver an oxidizing agent into the SCWO reactor;   receiving sensor data from the SCWO reactor indicating at least one of temperature, pressure, or oxidation status;   determining whether the SCWO reactor is operating within a predefined supercritical range based on the sensor data;   activating a flow control device to direct supercritical carbon dioxide (SCCO2) into an SCCO2 turbine when the SCCO2 meets predefined temperature and pressure conditions;   monitoring operating parameters of the SCCO2 turbine, including rotational speed and inlet pressure; and   controlling an output of a generator mechanically coupled to the turbine to maintain a target electrical output profile.   
     
     
         17 . The non-transitory, computer-readable medium of  claim 16 , the stages further comprising causing a carbon dioxide compressor to compress a cooled carbon dioxide stream for storage or reuse. 
     
     
         18 . The non-transitory, computer-readable medium of  claim 16 , the stages further comprising causing gas mixer to combine a compressed carbon dioxide with an oxidizing agent for reintroduction into the SCWO reactor. 
     
     
         19 . The non-transitory, computer-readable medium of  claim 16 , the stages further comprising causing a power phase synchronizer to match the phase, frequency, and voltage of the generator output to an external electrical grid. 
     
     
         20 . The non-transitory, computer-readable medium of  claim 16 , the stages further comprising monitoring temperature and pressure conditions within the SCWO reactor and adjusting the operation of the heating unit to maintain the reactor above the critical point of water.